FIELD OF THE INVENTION
[0001] The present invention relates to load bearing surfaces, and more particularly to
molded load bearing surfaces, such as the seat or back of a chair or bench, or the
support surface of a bed, cot or other similar product.
BACKGROUND OF THE INVENTION
[0002] US 2008/164 744 A1 discloses a method for making a plastic stool including a first step in which a first
thermoplastic material is ejected in a mold to form a frame, and a second step in
which a second thermoplastic material is formed as a seat surface insert which is
engaged with the open top of the frame. The seat surface insert is a softer material
than the frame. The seat surface has a connection ring to connect the surface to the
frame.
[0003] There are continuing efforts to develop new and improved load bearing surfaces. In
the context of general load bearing surfaces, the primary objectives of these efforts
are to obtain a durable and inexpensive load bearing surface. In the context of seating
and other body-support applications, it is also important to address comfort issues.
For example, with seating, it can be important to provide a surface that is comfortable
and does not create body fatigue over periods of extended use. Given that the load
characteristics (e.g. stiffness, resiliency, force/deflection profile) desired in
a particular surface will vary from application to application, it is also desirable
to have a load bearing surface that is easily tunable for different applications during
design and manufacture.
[0004] It is known to provide molded load bearing surfaces for a wide variety of applications.
For example, molded plastic chairs (e.g. lawn chairs) are available from a variety
of well known suppliers. Although these molded chairs provide an inexpensive seating
option, they do not provide the level of support and comfort available in more expensive
load bearing surfaces, such as conventional cushion sets. Rather, they provide an
essentially linear force/deflection profile, which gives the typical molded seating
surfaces the feel of a drum or a trampoline. In seating and other body-support applications,
this may result in an uncomfortable and sometimes ergonomically unacceptable load
bearing surface. Further, the ability to tune the characteristics of a conventional
molded seat is relatively limited. Different materials and different material thicknesses
can be used to provide a limited degree of control over the characteristics of the
seat, but this level of control is not sufficient in many applications.
[0005] To address the aforementioned limitations of molded loaded bearing surfaces, it is
also known to provide molded load bearing surfaces that are oriented after molding
to provide the desired load bearing surface characteristics, (See
US 2006/0267258A1). Oriented load bearing surfaces have proven to be a marked improvement over the
prior art in many ways.
SUMMARY OF THE INVENTION
[0006] The present invention provides a load bearing surface assembly having an oriented,
molded load bearing surface intersecured with a relatively rigid orienting member
according to claim 1. In one embodiment, the load bearing surface includes a pair
of orienting members mounted to opposed edges of the load bearing surface. The load
bearing surface may be integrally molded into a unitary construction with the orienting
member(s), for example, by placing the orienting member(s) in the mold cavity prior
to molding the load bearing surface.
[0007] In one embodiment, the orienting member includes a plurality of interlocking features
that provide a mechanical interlock between the load bearing surface and the orienting
member(s) during molding of the load bearing surface. In one embodiment, the interlocking
features are apertures that are filled with load bearing surface material when the
load bearing surface is molded onto the orienting member. The apertures may extend
in a direction substantially perpendicular to the direction of the tensile loads on
the load bearing surface. The size, shape, location and combined cross-sectional area
of the apertures may vary from application to application. In one embodiment, the
total projected cross sectional area is roughly equal to or greater than the total
maximum tensile loads multiplied by the shear strength of the material used to form
the load bearing surface. In one embodiment, the load bearing surface material has
a shear strength of 2,000 pounds per square inch.
[0008] In a second aspect, the present invention provides a method for manufacturing a load
bearing surface with an orienting member as defined in claim 7. It includes the general
steps of: (1) providing an orienting member; (2) placing the orienting member in a
mold cavity; (3) molding a load bearing surface onto the orienting member to form
a unitary structure; and (4) orienting the load bearing surface with an orienting
apparatus, the orienting apparatus mating with and using the orienting member to elongate
the load bearing surface. In one embodiment, the load bearing surface is provided
with a pair of orienting member disposed on opposed edges. This embodiment includes
the general steps of: (1) providing a pair of orienting members; (2) placing the orienting
member in a mold cavity at opposed ends of the mold cavity; (3) molding a load bearing
surface onto the orienting members to form a unitary structure; and (4) orienting
the load bearing surface with an orienting apparatus, the orienting apparatus mating
with both orienting members and moving the orienting members away from one another
to elongate the load bearing surface.
[0009] The present invention provide a simple and effective structure and method that facilitates
both manufacture and mounting of oriented, molded load bearing surfaces. The orienting
members provide a rigid structure that can be readily mounted to a support structure
using snaps, fasteners or other mounting elements. The orienting members also provide
the load bearing surface assembly with rigid edge members that can be easily engaged
by an orienting apparatus, thereby facilitating orientation of the load bearing surface
through elongation. The mechanical interlock between the orienting members and the
load bearing surface can be controlled in part through the design and configuration
of the interlocking features of the orienting member.
[0010] Other features and advantages of the invention will become apparent to those skilled
in the art upon review of the following detailed description, claims and drawings
in which like numerals are used to designate like features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011]
Fig. 1 is a perspective view of a load bearing surface having a pair of orienting
members according to an embodiment of the present invention.
Fig. 2 is an enlarged perspective view of a portion of the load bearing surface with
the encapsulated portions of the orienting member visible in hidden lines through
the material of the load bearing surface.
Fig. 3A is a cross-sectional view of the load bearing surface showing the interrelationship
between the load bearing surface and the orienting member.
Fig. 3B is an enlarged cross-sectional view of a portion the load bearing surface
showing the interrelationship between the load bearing surface and the orienting member.
Fig. 4 is a cross sectional view of a mold showing the orienting member in the mold
cavity before injection of the load bearing surface material.
Fig. 5 is a cross sectional view of a mold showing the orienting member in the mold
cavity after injection of the load bearing surface material.
Fig. 6 is a front view of an orienting apparatus in the process of orienting.
Fig. 7 is a front view of an orienting apparatus.
Fig. 8A is a perspective view of a portion of an alternative orienting member.
Fig. 8B is a cross sectional view of a mold showing the alternative orienting member
of Fig. 8A in the mold cavity after injection of the load bearing surface material.
Fig. 9 is a top plan view of an alternative load bearing surface.
Fig. 10A is an enlarged view of a portion of the alternative load bearing surface
of Fig. 9.
Fig. 10B is an enlarged view of a portion of the alternative load bearing surface
of Fig. 9 showing the connectors joined.
Fig. 11 is a representational view of a second alternative embodiment.
Fig. 12 is a perspective view of an orienting member of a third alternative embodiment.
Fig. 13 is a perspective view of a fourth alternative embodiment.
Fig. 14 is an enlarged perspective view of a portion of the fourth alternative embodiment.
Fig. 15 is a perspective view of a fifth alternative embodiment.
Fig. 16 is a top plan view of a plurality of interconnected load bearing surface assemblies.
Fig. 17A is a top plan view of an enlarged portion of the interconnected load bearing
surface assemblies.
Fig. 17B is a side elevational view of an enlarged portion of the interconnected load
bearing surface assemblies.
Fig. 18 is a perspective view showing the fifth alternative embodiment mounted to
a frame.
Fig. 19 is a perspective view of a sixth alternative embodiment.
[0012] Before the embodiments of the invention are explained in detail, it is to be understood
that the invention is not limited in its application to the details of construction
and the arrangement of the components set forth in the following description or illustrated
in the drawings. The invention is capable of other embodiments and of being practiced
or being carried out in various ways. Also, it is to be understood that the phraseology
and terminology used herein are for the purpose of description and should not be regarded
as limiting. The use of "including" and "comprising" and variations thereof is meant
to encompass the items listed thereafter and equivalents thereof as well as additional
items and equivalents thereof.
DESCRIPTION OF CURRENT EMBODIMENTS
[0013] A load bearing surface assembly 10 in accordance with one embodiment of the present
invention is shown in Fig. 1. The load bearing surface assembly 10 generally includes
a load bearing surface 12 and a pair of orienting members 14, 16 disposed on opposed
edges of the load bearing surface 12. The orienting members 14, 16 provide a rigid
edge member that may be used to orient the load bearing surface 12 and/or to mount
the load bearing surface 12 to a support structure.
[0014] In a second aspect, the present invention discloses a method for manufacturing a
load bearing surface assembly including the general steps of: (1) providing a pair
of orienting members 14, 16; (2) placing the orienting members 14, 16 in a mold cavity
at opposed ends of the mold cavity; (3) molding a load bearing surface 12 onto the
orienting members to form a load bearing surface assembly 10; and (4) orienting the
load bearing surface 12 with an orienting apparatus (not shown), the orienting apparatus
mating with both orienting members 14, 16 and moving the orienting members 14, 16
away from one another to elongate the load bearing surface 12.
[0015] In a third aspect, the present invention discloses a method for manufacturing and
mounting a load bearing surface assembly including the general steps of: (1) providing
a pair of orienting members 14, 16; (2) placing the orienting members 14, 16 in a
mold cavity at opposed ends of the mold cavity; (3) molding a load bearing surface
12 onto the orienting members to form a load bearing surface assembly 10; (4) orienting
the load bearing surface 12 with an orienting apparatus (not shown); and (5) mounting
the orienting members to a support structure. In one embodiment, the orienting step
may include the orienting apparatus mating with both orienting members 14, 16 and
moving the orienting members 14, 16 away from one another to elongate the load bearing
surface 12.
[0016] Referring now to Fig. 1, the illustrated load bearing surface assembly 10 is designed
to function as the support surface for the seat of a chair or as a portion of the
support surface for the seat of a chair. The present invention may, however, be incorporated
into essentially any application where a resilient load bearing surface may be desired.
In this embodiment, the load bearing surface assembly 10 includes a front edge 20,
a back edge 22, a right edge 24 and a left edge 26. Directions terms, such as "front,"
"back," "left," "right," "top" and "bottom," are used in reference to the physical
orientation shown in Fig. 1, and are not intended to limit the present invention to
use in applications in which the load bearing surface assembly 10 is disposed in any
specific orientation. The load bearing surface 12 includes a plurality of straps 28
that extend generally from the right edge 24 to the left edge 26. The straps 28 may
be coupled to one another to different degrees to provide a controlled amount of interdependence
between the straps 28 in the front-to-rear direction. For example, the straps 28 may
include bridges 30a, 30b that interconnect adjacent the straps 28. The bridges 30a,
30b are shaped and sized to provide the desired amount of coupling between adjacent
straps 28. The design and configuration of the bridges may vary from application to
application and even from location to location within a single application. Although
illustrated in connection with a load bearing surface 12 having a plurality of straps
28, the load bearing surface 12 may have essentially any configuration. For example,
the load bearing surface 12 may alternatively be a generally continuous sheet.
[0017] In the illustrated embodiment, the orienting members 14, 16 are disposed in opposition
to one another along the right edge 24 and the left edge 26, which facilitates orientation
of the load bearing surface 12 in the left-right direction and also facilitates mounting
of the load bearing surface at its left and right edges. In this embodiment, the tensile
loads encountered by the load bearing surface assembly 10 during orienting and after
being mounted to a support structure extend in the left-right direction. The orienting
members 14, 16 may be located along other edges or edge portions of the load bearing
surface, as desired.
[0018] Fig. 2 is an enlarged illustration of one end of the load bearing surface assembly
10 showing orienting member 14. In the illustrated embodiment, the orienting members
14, 16 are essentially identical to one another. This is not, however, necessary and
the orienting members may vary from one another. Given that they are essentially the
same, the two orienting members 14, 16 will be described by reference primarily to
orienting member 14. Orienting member 14 generally includes a head 30 and a projection
32. The head 30 is exposed and may include contours or other features (not shown)
intended to facilitate mating with an orienting machine for orienting purposes or
connection to a support structure to support the load bearing surface during end use.
For example, the head 30 may define screw or other fastener holes (not shown) for
mounting the head using screws or other fasteners. As another example, the head 30
may define include snap details (not shown) that allow the head 30 to be snap-fitted
onto an orienting machine and/or a support structure.
[0019] In the illustrated embodiment, the projection 32 is encapsulated in the load bearing
surface 12. The projection 32 includes a plurality of apertures 34 through which the
material of the load bearing surface 12 extends to mechanically knit the load bearing
surface 12 and the orienting member 14. In the illustrated embodiment, the apertures
34 extend through the projection 32 in a direction generally perpendicular to the
direction of the tensile loads to be encountered by load bearing surface assembly
10 during orientation and/or in final use as load bearing surface. The orientation
of the apertures 34 may vary from application to application. The apertures 34 of
the illustrated embodiment are generally square in cross-section, thereby providing
a surface that extends along a plane that is generally perpendicular to the direction
of the tensile loads (See Fig. 3A). The apertures 34 may vary from application to
application, as desired. For example, the apertures may be rectangular in cross-section
and still provide a surface that extends along a plane extending generally perpendicular
to the direction of the tensile loads. In other applications, the apertures may be
shaped in a way that does not provide a surface extending through a plane generally
perpendicular to the direction of the tensile loads. The apertures may vary in cross-sectional
shape along their length.
[0020] In the illustrated embodiment, the area of the load bearing surface material and
the area of the projection are substantially equal. More specifically, when viewed
in cross-section (see Fig. 3B), the area of each projection segment 36 is roughly
equal to the total area of load bearing surface material above, below and along each
side of the segment 36 (as represented by cross-hatched region A in Fig. 3B). In determining
this rough equivalence, the area extending to a point approximately mid-way between
adjacent segments 36 is considered.
[0021] Manufacture of the load bearing surface assembly 10 is described in connection with
Figs. 4-7. The orienting members 14, 16 are pre-manufactured. For example, the orienting
members 14, 16 may be injected molded using a conventional injection molding techniques
and apparatus. The apertures 34 may be formed during the molding process or may be
added to the orienting members 14, 16 in a subsequent manufacturing step. The orienting
members 14, 16 may be manufactured from a wide variety of materials having sufficient
hardness to withstand the forces to be encountered in the orienting process. In the
illustrated embodiment, the orienting members 14, 16 are manufactured from a plastic
material having a hardness that is an order of magnitude greater than the hardness
of the load bearing surface 12. However, the orienting members 14, 16 need not be
manufactured from plastic, but rather may be any material of hardness sufficient to
withstand the forces encountered during the orienting process. The specific hardness
may vary from application to application depending in large part on the characteristics
of the load bearing surface material and the amount of elongation to be achieved during
the orienting process.
[0022] Referring now to Fig. 4, the orienting members 14, 16 are placed in the mold cavity
80 for the load bearing surface 12. In the illustrated embodiment, the orienting members
14, 16 are disposed at opposed ends of the mold cavity 80. The orienting members 14,
16 are positioned with their respective projections 32 cantilevered into the mold
cavity 80. The mold cavity 80 may be shaped so that when it is fully closed it firmly
holds the orienting members 14, 16 in the appropriate position.
[0023] The load bearing surface 12 is next molded in place onto the orienting members 14,
16. The material of the load bearing surface 12 is introduced into the mold cavity
80, which in the illustrated embodiment may be achieved using conventional molding
techniques and apparatus. The load bearing surface material in this embodiment may
be a thermoplastic elastomer, such COPE (copolymer polyester), nylon-based TPE or
a thermoplastic urethane. The introduced material flows through and substantially
fills the mold cavity 80. In doing so, the material flows through the apertures 34
in the orienting members 14, 16, which is perhaps best shown in Fig. 5. The material
is held in the mold until it is sufficiently cured. Once cured, the load bearing surface
12 and the orienting members 14, 16 are mechanically knitted together forming a load
bearing surface assembly 10 that is essentially a unitary structure. In some applications,
there may also be an adhesive bond between the load bearing surface 12 and the orienting
members 14, 16.
[0024] Once the load bearing surface assembly 10 is formed, the load bearing surface 12
is oriented to give it the desired physical characteristics. For example, the load
bearing surface 12 may be intentionally and permanently deformed in the direction
along which the principle tensile loads will run during use. By doing this prior to
actual use, undesired deformation (or creep) that might otherwise occur from loading
during use can be limited and potentially avoided altogether. In anticipation of orienting,
the load bearing surface 12 is intentionally designed smaller than it's "in use" size
by the amount it will be enlarged by the permanent deformation brought on by the orienting
process. In effect, the orienting process forces the creep to occur in large part
prior to actual use instead of during use of the load bearing surface assembly 10.
Forcing this creep to occur in the manufacturing environment allows it to happen in
a controlled and repeatable manner. The load bearing surface assembly 10 shown in
Figs. 1-5 may be manufactured using essentially any type of orienting apparatus capable
of gripping the orienting members and applying the desired stretch to the load bearing
surface. Figs. 6 and 7 show an orienting apparatus 100 capable of orienting the load
bearing surface assembly 10 shown in Figs. 1-5. The orienting apparatus 100 generally
includes a pair of clamps 102, 104 that may be closed on the orienting members 14,
16. The clamps 102, 104 may include jaws that are shaped to mate with the orienting
members 14, 16. For example, the orienting members 14, 16 may include protrusions
or other surface contours that provide a strong interconnection with the clamps 102,
104. The jaws of the clamps 102, 104 may be held in the closed position by bolts or
other fasteners, if desired. In the illustrated embodiment, the upper clamp 102 is
movably mounted to the orienting apparatus so that the distance between the two clamps
102, 104 may be varied. The movable clamp 102 may be mounted on a carriage 106 that
is connected to a hydraulic cylinder (not identified) or other mechanism capable of
providing the carriage 106 with linear motion. Extension and retraction of the cylinder
108 may be used to move the carriage 106 and consequently the movable clamp 102 (compare
Figs. 6 and 7). The amount of stretch applied to the load bearing surface may vary
from application to application. However, in the illustrated embodiment, the load
bearing surface 10 may be stretched in the range of approximately twice to approximately
six times its original length.
[0025] Once included in the load bearing surface assembly 10, the orienting members 14,
16 may be used to mount the load bearing surface assembly 10 to a support structure
(not shown). For example, the orienting members 14, 16 may be secured to a support
frame (not shown) by fasteners (not shown). The support frame may be a peripheral
structure. If desired, the orienting members 14, 16 may include holes or other fastener
details that facilitate mating of the orienting members 14, 16 with the orienting
apparatus 100 and/or facilitate mounting of the load bearing surface assembly 10 to
a support structure in its end use.
[0026] As noted above, the load bearing surface assembly 10 of the illustrated generally
includes a load bearing surface 12 and a pair of orienting members 14, 16. Although
shown with a pair of orienting members 14, 16, the number of orienting members may
vary from application to application depending in large part on the design and configuration
of the load bearing surface 12, the support structure (not shown) and the orienting
apparatus (not shown). In some applications, a load bearing surface assembly 10 may
include only a single orienting member, while in others the number of orienting members
may be as large as desired. In the illustrated embodiment, the pair of orienting members
14, 16 are used to orient the load bearing surface 12 and to mount the load bearing
surface assembly 10 to a support structure. It is not necessary for all of the orienting
members in a single load bearing surface assembly to perform both functions. For example,
in other applications, any given orienting member in a load bearing surface assembly
may be used for orienting, for mounting or for both purposes.
[0027] In the illustrated embodiment, the load bearing surface 12 and the orienting members
14, 16 are mechanically knitted by the flow of load bearing surface material through
apertures 34 in the projection 32. These components can be interconnected using alternative
mechanical structures. For example, as shown in Figs. 8A and 8B, the orienting member
14' may define a channel 32' and include a plurality of posts 34' that extend across
the channel 32'. The size, shape, spacing and configuration of the posts may vary
from application to application. In use, the posts 34' are entrapped by the flow of
load bearing surface material 12' during the molding process, as shown by Fig. 8B.
[0028] An alternative load bearing surface assembly 210 is shown in Figs. 9 and 10A-B. In
this embodiment, the orienting members 214, 216 include integral attachment features.
More specifically, the orienting members 214, 216 include tabs 217. The tabs 217 may
be "barbed" so that they may be snap-fitted into corresponding openings in a support
structure (not shown). The orienting apparatus may also include contours that closely
interfit with the tabs 217. For example, the orienting apparatus may include jaws
that close on the tabs 217. The jaws may be contoured to match the shape of the tabs
217. Figs. 9 and 10A show the apertures 234 in the orienting member 214 in hidden
lines. As shown, the apertures 234 are generally circular in cross-section and are
arranged in two offset rows along the projection 232 of the orienting member 214.
The apertures 234 could vary in size, spacing, arrangement and cross-sectional shape
from application to application.
[0029] It may be desirable to combine a plurality of load bearing surface assemblies to
provide a larger support structure. For example, two or more load bearing surface
assemblies may be positioned adjacent to one another to cooperatively provide a larger
support surface (See e.g. Fig. 16). It may be desirable in some applications to interconnect
adjacent load bearing surfaces. Among other things, this may help to prevent the two
load bearing surface assemblies from separating under a load and may give the two
assemblies some interdependency in terms of support and movement. The embodiment of
Figs. 9 and 10 includes integral attachments for intersecuring adjacent load bearing
surface assemblies. More specifically, a load bearing surface assembly 210 of this
embodiment may include four male connectors 250 and four female connectors 252. The
male connector 250 includes a head 254 and the female connector 252 defines an aperture
256. In use, the male connectors 250 of one load bearing surface assembly 210 can
be interfitted with the corresponding female connectors 252 of an adjacent load bearing
surface assembly 210 to join the two assemblies. For example, Fig. 10B shows a male
connector 250 of one assembly 210 fitted through the opening in the female connector
252 of another assembly 210. During assembly, the male connectors 250 are pulled through
the apertures 256 in the female connectors 252 until the heads 254 pass through the
aperture 256 to lock the connectors 250, 252 together. The connectors 250, 252 may
be of various configurations depending on a variety factors, such as the desired characteristics
of the load bearing surface assembly, the desired tension in the connectors, the amount
of force desired for joining the connectors, the amount of force desired to separate
the connectors once attached and the amount of elasticity and interdependence desired
between adjacent load bearing surface assemblies. The design and configuration of
the connectors of load bearing surface assembly 210 is merely exemplary. The number,
size, shape and configuration of the connectors may vary from application to application
as desired. For example, the connectors need not be evenly spaced and need not be
identical to one another. Further, it is not necessary for all of the male connectors
to be on one side and all of the female connectors to be on the other. Rather, they
may be comingled as desired provided that a matching arrangement is used on the opposite
side. In the illustrated embodiment, the connectors are not oriented, but it should
be understood that they can be oriented if desired.
[0030] A second alternative embodiment of the load bearing surface assembly 310 is shown
in Fig. 11. In this embodiment, the orienting member 314 includes two projections
332. The projections 332 each define a plurality of apertures 334. The load bearing
surface 312 is molded in place on the projections 332, thereby providing a unitary
assembly.
[0031] Fig. 12 shows another alternative orienting member 414. In this embodiment, the orienting
member 414 includes two projections 432, and each projection 432 defines three apertures
434. Additionally, the head 430 of the orienting member 414 defines a plurality of
apertures 435. In this embodiment, the head 430 and projections 432 may be exposed
within the mold cavity so that the material of the load bearing surface flows through
and mechanically interlocks with the head 430 and the projections 432.
[0032] In some applications, the orienting members may be a mounted to a support structure
without a separate support frame. For example, as shown in Figs. 13 and 14 the load
bearing surface assembly 510 may include orienting members 514 (only one shown) that
are designed to function as a chair seat or chair back frame. In this embodiment,
the orienting members 514 are contoured to provide the desired aesthetic appearance
and are configured to mount directly to the underlying support structure without a
separate frame. For example, the orienting members 514 may be positioned along the
left and right ends of the load bearing surface assembly 510. The orienting members
514 may be mounted to support structures extending along the left and right sides
of the chair to provide a suspended seat structure. This embodiment eliminates the
use of a separate peripheral frame to support the load bearing surface assembly 510
and may therefore reduce cost in some applications. The load bearing surface material
512 shows the apertures 534 in the orienting member 514 in hidden lines. As shown,
the apertures 534 are generally triangular in cross-section and are arranged in two
rows. The apertures 534 could vary in size, spacing, arrangement and cross-sectional
shape from application to application.
[0033] A fourth alternative embodiment is shown in Figs. 15-18. This embodiment is similar
to the embodiment of Figs. 9 and 10A-B in that the load bearing surface assemblies
(See Fig. 15) can be used in modular applications where it is desirable to combine
a plurality of load bearing surfaces to provide a larger support surface (See Fig.
16). In this embodiment, each load bearing surface assembly 610 includes three sets
of integral connectors 630 and 632. More specifically, in this embodiment, each load
bearing surface assembly 610 includes three male connectors 630 extending from one
side of the load bearing surface assembly 610 and three female connectors 632 extending
from the opposite side. The connectors may or may not be aligned with bridges 628
extending laterally across the load bearing surface assembly depending in part on
the desired support characteristics of the overall surface. For example, in the embodiment
of Figs. 15-18, the central set of connectors is aligned with bridges 628 extending
laterally across the load bearing surface assembly, while the other two sets of connectors
are not.
[0034] Fig. 16 shows three load bearing surface assemblies 610 joined together by the connectors.
In this embodiment, the male connectors of one load bearing surface assembly are interfitted
with the corresponding female connectors of the adjacent load bearing surface assembly.
Although Fig. 16 shows three assemblies joined together, the number of interconnected
load bearing surface assemblies 610 may differ from application to application. For
example, in some applications only two load bearing surface assemblies may be joined
together and in other applications more than three load bearing surface assemblies
may be ganged together.
[0035] As noted above, the design and configuration of the connectors may vary from application
to application. However, in the illustrated embodiment, each male connector 630 may
include a head 634 with a tapered nose 640 and a flat tail 642, and each female connector
632 may define an aperture 636 shaped to receive the head 634 (See Fig. 15). The tapered
nose 640 may facilitate insertion of the head 634 into the aperture 636 of the female
connector 632. The surfaces of the female connector that define the aperture 636 may
include a shoulder 644 shaped to seat the tail 642 of the head 634 (See Fig. 17A).
The interface between the flat tail 642 and the shoulder 644 may be configured to
resist separation of the head 634 from the female connector 632. If desired, the interfacing
surfaces of the tail 642 and/or the shoulder 644 may be angled inwardly to draw together
opposite sides of the female connector 632 when forces tending to pull apart the two
load bearing surface assemblies are encountered. As shown in Figs. 17B, this embodiment
may provide the connectors 630 and 632 with a relatively flat profile that does not
exceed the thickness of the main portion of the load bearing surface assembly. Accordingly,
the connectors need not increase the space required to accommodate the load bearing
surface assemblies and may not be felt by a user seated or otherwise supported on
the surface.
[0036] A load bearing surface assembly with integral connectors may benefit from also including
integral orienting members as discussed above in connection with the embodiments of
Figs. 1-14. However, a load bearing surface assembly need not include integral orienting
members to within the scope of this aspect of the invention. For example, the embodiment
of Figs. 15-18 does not include integral orienting members. Instead, it includes an
integral attachment edges that can be fitted into a frame or other structural member.
Fig. 18 shows one end of the load bearing surface assembly 610 mounted to a frame
670. The opposite end may be mounted in a like manner. The size of the load bearing
surface assembly 610 and the spacing between opposite sides of the frame 670 may be
selected to place the assembly 610 under the desired tension. For example, it may
be desirable to preload the load bearing surface assembly 610 so that it provides
the desired support and cushioning characteristics. When smaller than the distance
between opposite frames 670, the load bearing surface assembly 610 is stretched for
installation on the frame 670 and is held in a stretched condition once installed.
Referring now to Fig. 18, opposite edges 660 of the load bearing surface assembly
610 may be formed with integral attachment details 662. The edges 660 of the illustrated
embodiment are used for mounting by turning the edges 660 in a direction perpendicular
to the primary extent of the load bearing surface assembly 610 and fitting them into
corresponding slots 670 in opposite frames 672 (or other structural member). Tension
in the load bearing surface assembly may be used to help retain the attachment details
662 in the slots 670. Additionally (or in the alternative), fasteners (such as screws)
may be used to secure the edge to the frame or other structural member.
[0037] Although the Figs. 15-18 show an embodiment with three sets of connectors spaced
evenly along opposite edges of the load bearing surface assembly, that construction
is merely exemplary. The number and spacing of connectors may vary depending on a
variety of factors, including anticipated load and desired support characteristics.
For example, as shown in Fig. 19, the load bearing surface assembly 710 may include
seven sets of connectors, each set including a male connector 730 and a female connector
732. The connectors are arranged with one set of connectors in the middle of the assembly
and three sets of connectors grouped together toward opposite ends of the assembly.
In this embodiment, five sets of connectors are aligned with bridges 728 extending
across the load bearing surface assembly 710 and two sets of connectors are not.
[0038] Adjacent load bearing surface assemblies may be joined using essentially any assembly
equipment capable of interfitting the male and female connectors. In some applications,
this may be done manually. In one embodiment, the assembly machine (not shown) includes
fixtures that hold adjacent load bearing surface assemblies. The fixtures may hold
the entire assemblies or may hold only portions of the assemblies. For example, the
fixtures may hold only the connectors that are being joined. In this embodiment, the
fixtures hold the parts so that the male and female connectors overlap. The assembly
machine includes a mandrel or other similar component that applies force to the male
and female connectors in a direction perpendicular to extent of the load bearing surface
assembly. A sufficient amount of force is applied to cause the male and female connectors
to snap into engagement. With regard to the load bearing surface assembly 710, the
mandrel will force the head of the male connector through the aperture in the female
connector. In another embodiment, the male and female connectors are joined after
the load bearing surface assemblies have been installed on the frame (or other support
structure). In this embodiment, the frame essentially functions as the fixture for
holding the load bearing surface assemblies in position while a mandrel or other similar
component applies the perpendicular force required to join the connectors. The apparatus
and methods used to join the connectors may vary from application to application depending
in part on the design and configuration of the connectors.
1. A load bearing surface assembly (10; 210; 310; 510; 610; 710), comprising:
a molded load bearing surface (12) being permanently deformed, i.e. oriented in the
direction along which the principle tensile loads will run in use, said load bearing
surface (12) having elastomeric properties allowing said load bearing surface (12)
to flex under anticipated loads; and
at least one orienting member (14, 16; 214, 216; 314; 414; 514), said load bearing
surface (12) molded onto said orienting member, said orienting member (14, 16; 214,
216; 314; 414; 514) having a hardness greater than a hardness of said load bearing
surface (12), and being sufficiently rigid to provide a structural component for gripping
said orienting member (14, 16; 214, 216; 314; 414; 514) of said load bearing surface
assembly (10; 210; 310; 510; 610; 710) during orienting of said load bearing surface
(12) and for mounting said load bearing surface assembly (10; 210; 310; 510; 610;
710) to a support structure.
2. The assembly of claim 1 including at least a first orienting member (14; 214; 314;
414; 514) and a second orienting member (16; 216).
3. The assembly of claim 2 wherein said load bearing surface includes a pair of opposed
edges (24, 26);
said load bearing surface (12) being molded at a first of said opposed edges (24,
26) onto said first orienting member (14; 214; 314; 414; 514); and
said load bearing surface (12) being molded at a second of said opposed edges (24,
26) onto said second orienting member (16; 216).
4. The assembly of anyone of claims 2 or 3 wherein at least one of said orienting members
(14, 16; 214, 216; 314; 414; 514) includes an interlocking feature (34; 434, 435)
to provide a mechanical interlock between said load bearing surface (12) and said
orienting member (14, 16; 214, 216; 314; 414; 514).
5. The assembly of claim 4 wherein said interlocking feature is further defined as a
plurality of apertures (34; 434, 435) defined through said orienting member (14, 16;
414) in a direction substantially perpendicular to a direction of anticipated tensile
loads on said load bearing surface (12) during use of said assembly, said apertures
having a cumulative cross-sectional area approximately equal to or greater than a
total of anticipated maximum tensile loads multiplied by a shear strength of said
load bearing surface material.
6. The assembly of anyone of the preceding claims wherein said load bearing surface (12)
includes integral connectors (250, 252; 630, 632; 730, 732), said integral connectors
configured to allow interconnection between adjacent load bearing surface assemblies.
7. A method for manufacturing a load bearing surface (12), comprising the steps of:
providing a first orienting member (14; 214; 314; 414; 514) having a hardness;
placing the first orienting member (14; 214; 314; 414; 514) in a mold cavity;
molding a load bearing surface (12) onto the first orienting member (14; 214; 314;
414; 514) to form a unitary structure; and
orienting the molded load bearing surface (12) using an orienting apparatus capable
of elongating the load bearing surface (12), the orienting apparatus mating with and
using the first orienting member (14; 214; 314; 414; 514) to elongate the load bearing
surface (12), the oriented load bearing surface (12)
having a hardness that is less than the hardness of said first orienting member (14;
214; 314; 414; 514).
8. The method of claim 7 further including the steps of:
providing a second orienting member (16; 216); and
placing the second orienting member (16; 216) in the mold cavity;
wherein said molding step is further defined as molding a load bearing surface (12)
onto the first orienting member (14; 214; 314; 414; 514) and the second orienting
member (16; 216) to form a unitary structure; and
wherein said orienting step is further defined as orienting the molded load bearing
surface (12) using an orienting apparatus capable of elongating the load bearing surface
(12), the orienting apparatus mating with and using the first orienting member and
the second orienting member (14, 16; 214, 216; 314; 414; 514) to elongate the load
bearing surface (12).
9. The method of claim 8 wherein the mold cavity is shaped to define the load bearing
surface (12) with a pair of opposed edges (24, 26); and
wherein said first placing step is further defined as placing the first orienting
member (14; 214; 314; 414; 514) in the mold cavity along a first of the opposed edges
(24, 26); and
wherein said second placing step is further defined as placing the second orienting
member (16; 216) in the mold cavity along a second of the opposed edges (24, 26).
10. The method of claim 8 or 9 wherein said orienting step is further defined as orienting
the molded load bearing surface (12) using an orienting apparatus capable of elongating
the load bearing surface (12), the orienting apparatus mating solely with the first
orienting member (14; 214; 314; 414; 514) and the second orienting member (16; 216),
the orienting apparatus moving the first orienting member (14; 214; 314; 414; 514)
and the second orienting member (16; 216) apart to elongate the load bearing surface
(12).
11. The method of anyone of claims 8 to 10 further including the step of mounting the
load bearing assembly (10; 210; 310; 510; 610; 710) to a support structure, said mounting
step including securing the first orienting member (14; 214; 314; 414; 514) to the
support structure and securing the second orienting member (16; 216) to the support
structure, the first orienting member (14; 214; 314; 414; 514) and the second orienting
member (16; 216) being mounted apart from one another a distance determine to suspend
the load bearing surface (12) at a desired tension.
12. The method of anyone of claims 7 to 11 further including the step of mounting the
load bearing assembly (10; 210; 310; 510; 610; 710) to a support structure, said mounting
step including securing the orienting member (14, 16; 214, 216; 314; 414; 514) to
the support structure.
13. The method of anyone of claims 7 to 12 further including the steps of:
providing the load bearing surface (12) with a set of integral connectors (250, 252;
630, 632; 730, 732) for joining adjacent load bearing assemblies (10; 210; 310; 510;
610; 710), the set of integral connectors including a first connector (250; 630; 730)
on one side of the load bearing surface (12) and a second connector (252; 632; 732)
on the opposite side of the load bearing surface (12), the first connector being configured
to interconnect with the second connector (252; 632; 732) and
interconnecting a first load bearing surface assembly (10; 210; 310; 510; 610; 710)
to a second load bearing surface assembly (10; 210; 310; 510; 610; 710) by interconnecting
the first connector (250; 630; 730) of the first load bearing surface assembly with
the second connector (252; 632; 732) of the second load bearing surface assembly.
1. Lasttragende Oberflächenanordnung (10; 210; 310; 510; 610; 710), umfassend:
eine geformte Lastoberfläche (12), die permanent verformt wird, d. h. in die Richtung
ausgerichtet wird, entlang der die Hauptzuglasten bei der Verwendung verlaufen, wobei
die lasttragende Oberfläche (12) elastomere Eigenschaften aufweist, die ermöglichen,
dass sich die lasttragende Oberfläche (12) unter antizipierten Lasten beugt; und
mindestens ein Ausrichtungselement (14, 16; 214, 216; 314; 414; 514), wobei die lasttragende
Oberfläche (12) auf das Ausrichtungselement aufgeformt ist, wobei das Ausrichtungselement
(14, 16; 214, 216; 314; 414; 514) eine Härte aufweist, die größer als eine Härte der
lasttragenden Oberfläche (12) ist, und ausreichend steif ist, um eine Strukturkomponente
zum Greifen des Ausrichtungselements (14, 16; 214, 216; 314; 414; 514) der lasttragenden
Oberflächenanordnung (10; 210; 310; 510; 610; 710) während des Ausrichtens der lasttragenden
Oberfläche (12) und zum Montieren der lasttragenden Oberflächenanordnung (10; 210;
310; 510; 610; 710) an einer Stützstruktur bereitzustellen.
2. Anordnung nach Anspruch 1, die mindestens ein erstes Ausrichtungselement (14; 214;
314; 414; 514) und ein zweites Ausrichtungselement (16; 216) aufweist.
3. Anordnung nach Anspruch 2, wobei die lasttragende Oberfläche ein Paar gegenüberliegender
Ränder (24, 26) aufweist;
wobei die lasttragende Oberfläche (12) an einem ersten der gegenüberliegenden Ränder
(24, 26) auf das erste Ausrichtungselement (14; 214; 314; 414; 514) aufgeformt ist;
und
wobei die lasttragende Oberfläche (12) an einem zweiten der gegenüberliegenden Ränder
(24, 26) auf das zweite Ausrichtungselement (16; 216) aufgeformt ist.
4. Anordnung nach einem der Ansprüche 2 oder 3, wobei mindestens eines der Ausrichtungselemente
(14, 16; 214, 216; 314; 414; 514) ein Verriegelungsmerkmal (34; 434, 435) zum Bereitstellen
einer mechanischen Verriegelung zwischen der lasttragenden Oberfläche (12) und dem
Ausrichtungselement (14, 16; 214, 216; 314; 414; 514) aufweist.
5. Anordnung nach Anspruch 4, wobei das Verriegelungsmerkmal weiter als mehrere Öffnungen
(34; 434, 435) definiert wird, die von dem Ausrichtungselement (14, 16; 414) in eine
Richtung definiert werden, die im Wesentlichen senkrecht zu einer Richtung antizipierter
Zuglasten auf der lasttragenden Oberfläche (12) während der Verwendung der Anordnung
definiert wird, wobei die Öffnungen einen kumulativen Querschnittsbereich aufweisen,
der gleich oder größer als eine Gesamtheit der antizipierten maximalen Zuglasten multipliziert
mit einer Scherstärke des lasttragenden Oberflächenmaterials ist.
6. Anordnung nach einem der vorherigen Ansprüche, wobei die lasttragende Oberfläche (12)
integrierte Steckverbinder (250, 252; 630, 632; 730, 732) aufweist, wobei die integrierten
Steckverbinder zum Ermöglichen der Verbindung zwischen benachbarten lasttragenden
Oberflächenanordnungen konfiguriert sind.
7. Verfahren zum Herstellen einer lasttragenden Oberfläche (12), wobei das Verfahren
die folgenden Schritte umfasst: Bereitstellen eines Ausrichtungselements (14; 214;
314; 414; 514) mit einer Härte; Anordnen des ersten Ausrichtungselements (14; 214;
314; 414; 514) in einem Formhohlraum; Aufformen einer lasttragenden Oberfläche (12)
auf das erste Ausrichtungselement (14; 214; 314; 414; 514) zum Formen einer einheitlichen
Struktur; und
Ausrichten der lasttragenden Formfläche (12) unter Verwendung einer Ausrichtungsvorrichtung,
welche die lasttragende Oberfläche (12) verlängern kann, wobei die Ausrichtungsvorrichtung
in dem ersten Ausrichtungselement (14; 214; 314; 414; 514) steckt und dies verwendet,
um die lasttragende Oberfläche (12) zu verlängern, wobei die lasttragende Oberfläche
(12) eine Härte aufweist, die geringer als die Härte des ersten Ausrichtungselements
(14; 214; 314; 414; 514) ist.
8. Verfahren nach Anspruch 7, weiterhin umfassend die folgenden Schritte: Bereitstellen
eines zweiten Ausrichtungselements (16; 216); und Anordnen des zweiten Ausrichtungselements
(16; 216) in dem Formhohlraum;
wobei der Formschritt ferner als Aufformen einer lasttragenden Oberfläche (12) auf
das erste Ausrichtungselement (14; 214; 314; 414; 514) und das zweite Ausrichtungselement
(16; 216) zum Formen einer einheitlichen Struktur definiert wird; und
wobei der Ausrichtungsschritt weiterhin als Ausrichten der lasttragenden Formfläche
(12) unter Verwendung einer Ausrichtungsvorrichtung definiert wird, welche die lasttragende
Oberfläche (12) verlängern kann, wobei die Ausrichtungsoberfläche in dem ersten Ausrichtungselement
und dem zweiten Ausrichtungselement (14, 16; 214, 216; 314; 414; 514) steckt und diese
verwendet, um die lasttragende Oberfläche (12) zu verlängern.
9. Verfahren nach Anspruch 8, wobei der Formhohlraum eine Form aufweist, um die lasttragende
Oberfläche (12) mit einem Paar gegenüberliegender Ränder (24, 26) zu definieren; und
wobei der erste Anordnungsschritt weiterhin als Anordnen des ersten Ausrichtungselements
(14; 214; 314; 414; 514) in dem Formhohlraum entlang eines ersten der gegenüberliegenden
Ränder (24, 26) definiert ist; und
wobei der zweite Anordnungsschritt weiterhin als Anordnen des zweiten Ausrichtungselements
(16; 216) in dem Formhohlraum entlang eines zweiten der gegenüberliegenden Ränder
(24, 26) definiert wird.
10. Verfahren nach Anspruch 8 oder 9, wobei der Ausrichtungsschritt weiterhin als Ausrichten
der lasttragenden Formfläche (12) unter Verwendung einer Ausrichtungsvorrichtung definiert
wird, welche die lasttragende Oberfläche (12) verlängern kann, wobei die Ausrichtungsvorrichtung
nur in dem ersten Ausrichtungselement (14; 214; 314; 414; 514) und dem zweiten Ausrichtungselement
(16; 216) steckt, wobei die Ausrichtungsvorrichtung das erste Ausrichtungselement
(14; 214; 314; 414; 514) und das zweite Ausrichtungselement (16; 216) wegbewegt, um
die lasttragende Oberfläche (12) zu verlängern.
11. Verfahren nach einem der Ansprüche 8 bis 10, das weiterhin den Schritt des Montierens
der lasttragenden Anordnung (10; 210; 310; 510; 610; 710) an einer Stützstruktur beinhaltet,
wobei der Montageschritt das Sichern des ersten Ausrichtungselements (14; 214; 314;
414; 514) an der Stützstruktur und das Sichern des zweiten Ausrichtungselements (16;
216) an der Stützstruktur beinhaltet, wobei das erste Ausrichtungselement (14; 214;
314; 414; 514) und das zweite Ausrichtungselement (16; 216) voneinander in einem bestimmten
Abstand montiert werden, um die lasttragende Vorrichtung (12) mit einer gewünschten
Spannung aufzuhängen.
12. Verfahren nach einem der Ansprüche 7 bis 11, ferner umfassend den Schritt des Montierens
der lasttragenden Anordnung (10; 210; 310; 510; 610; 710) an einer Stützstruktur,
wobei der Montageschritt das Sichern des Ausrichtungselements (14, 16; 214, 216; 314;
414; 514) an der Stützstruktur beinhaltet.
13. Verfahren nach einem der Ansprüche 7 bis 12, ferner umfassend die folgenden Schritte:
Bereitstellen der lasttragenden Oberfläche (12) mit einem Satz integrierter Steckverbinder
(250, 252; 630, 632; 730, 732) zum Verbinden benachbarter lasttragender Anordnungen
(10; 210; 310; 510; 610; 710), wobei der Satz integrierter Steckverbinder einen ersten
Steckverbinder (250; 630; 730) auf einer Seite der lasttragenden Oberfläche (12) und
einen zweiten Steckverbinder (252; 632; 732) auf der gegenüberliegenden Seite der
lasttragenden Oberfläche (12) aufweist, wobei der erste Steckverbinder zum Verbinden
mit dem zweiten Steckverbinder (252; 632; 732) konfiguriert ist; und
Verbinden einer ersten lasttragenden Oberflächenanordnung (10; 210; 310; 510; 610;
710) mit einer zweiten lasttragenden Oberflächenanordnung (10; 210; 310; 510; 610;
710) durch Verbinden des ersten Steckverbinders (250; 630; 730) der ersten lasttragenden
Oberflächenanordnung mit dem zweiten Steckverbinder (252; 632; 732) der zweiten lasttragenden
Oberflächenanordnung.
1. Ensemble de surface de support de charge (10 ; 210 ; 310 ; 510 ; 610 ; 710), comprenant
:
une surface de support de charge moulée (12) déformée de manière permanente, c'est-à-dire
orientée dans la direction le long de laquelle les charges de traction principales
s'appliquent pendant l'utilisation, ladite surface de support de charge (12) ayant
des propriétés élastomères permettant à ladite surface de support de charge (12) de
fléchir sous l'effet de charges anticipées ; et
au moins un organe d'orientation (14, 16 ; 214, 216 ; 314 ; 414 ; 514), ladite surface
de support de charge (12) étant moulée sur ledit organe d'orientation, ledit organe
d'orientation (14, 16 ; 214, 216 ; 314 ; 414 ; 514) ayant une dureté supérieure à
une dureté de ladite surface de support de charge (12), et étant suffisamment rigide
pour constituer un composant structurel pour permettre la préhension dudit organe
d'orientation (14, 16 ; 214, 216 ; 314 ; 414 ; 514) dudit ensemble de surface de support
de charge (10 ; 210 ; 310 ; 510 ; 610 ; 710) lors de l'orientation de ladite surface
de support de charge (12) et pour monter ledit ensemble de surface de support de charge
(10 ; 210 ; 310 ; 510 ; 610 ; 710) sur une structure de support.
2. Ensemble selon la revendication 1, comportant au moins un premier organe d'orientation
(14 ; 214 ; 314 ; 414 ; 514) et un deuxième organe d'orientation (16 ; 216).
3. Ensemble selon la revendication 2, dans lequel ladite surface de support de charge
comporte une paire de bords opposés (24, 26) ;
ladite surface de support de charge (12) étant moulée au niveau d'un premier desdits
bords opposés (24, 26) sur ledit premier organe d'orientation (14 ; 214 ; 314 ; 414
; 514) ; et ladite surface de support de charge (12) étant moulée au niveau d'un deuxième
desdits bords opposés (24, 26) sur ledit deuxième organe d'orientation (16 ; 216).
4. Ensemble selon l'une quelconque des revendications 2 ou 3, dans lequel au moins l'un
desdits organes d'orientation (14, 16 ; 214, 216 ; 314 ; 414 ; 514) comporte un élément
d'emboîtement (34 ; 434, 435) pour fournir un emboîtement mécanique entre ladite surface
de support de charge (12) et ledit organe d'orientation (14, 16 ; 214, 216 ; 314 ;
414 ; 514).
5. Ensemble selon la revendication 4, dans lequel ledit élément d'emboîtement est en
outre défini comme une pluralité d'ouvertures (34 ; 434, 435) définies à travers ledit
organe d'orientation (14, 16 ; 414) dans une direction sensiblement perpendiculaire
à une direction de charges de traction anticipées appliquées sur ladite surface de
support de charge (12) au cours de l'utilisation dudit ensemble, lesdites ouvertures
ayant une surface en section transversale cumulée approximativement supérieure ou
égale à un total des charges de traction maximales anticipées multiplié par une résistance
au cisaillement dudit matériau de surface de support de charge.
6. Ensemble selon l'une quelconque des revendications précédentes, dans lequel ladite
surface de support de charge (12) comportent des connecteurs intégrés (250, 252 ;
630, 632 ; 730, 732), lesdits connecteurs intégrés étant configurés pour permettre
une interconnexion entre des ensembles de surface de support de charge adjacents.
7. Procédé de fabrication d'une surface de support de charge (12), comprenant les étapes
suivantes :
fournir un premier organe d'orientation (14 ; 214 ; 314 ; 414 ; 514) ayant une certaine
dureté ;
placer le premier organe d'orientation (14 ; 214 ; 314 ; 414 ; 514) dans une cavité
de moule ;
mouler une surface de support de charge (12) sur le premier organe d'orientation (14
; 214 ; 314 ; 414 ; 514) pour former une structure unitaire ; et orienter la surface
de support de charge moulée (12) en utilisant un appareil d'orientation capable d'allonger
la surface de support de charge (12), l'appareil d'orientation s'accouplant avec,
et utilisant, le premier organe d'orientation (14 ; 214 ; 314 ; 414 ; 514) pour allonger
la surface de support de charge (12), la surface de support de charge orientée (12)
ayant une dureté qui est inférieure à la dureté dudit première organe d'orientation
(14 ; 214 ; 314 ; 414 ; 514).
8. Procédé selon la revendication 7, comportant en outre les étapes suivantes :
fournir un deuxième organe d'orientation (16 ; 216) ; et
placer le deuxième organe d'orientation (16 ; 216) dans la cavité du moule ;
ladite étape de moulage étant en outre définie comme le moulage d'une surface de support
de charge (12) sur le premier organe d'orientation (14 ; 214 ; 314 ; 414 ; 514) et
sur le deuxième organe orientation (16 ; 216) pour former une structure unitaire ;
et
ladite étape d'orientation étant en outre définie comme l'orientation de la surface
de support de charge moulée (12) en utilisant un appareil d'orientation capable d'allonger
la surface de support de charge (12), l'appareil d'orientation s'accouplant avec,
et utilisant, le premier organe d'orientation et le deuxième organe orientation (14,
16 ; 214, 216 ; 314, 414 ; 514) pour allonger la surface de support de charge (12).
9. Procédé selon la revendication 8, dans lequel la cavité du moule est formée de manière
à définir la surface de support de charge (12) avec une paire de bords opposés (24,
26) ; et
ladite première étape de positionnement étant en outre définie comme le positionnement
du premier organe d'orientation (14 ; 214 ; 314 ; 414 ; 514) dans la cavité du moule
le long d'un premier des bords opposés (24, 26) ; et
ladite deuxième étape de positionnement étant en outre définie comme le positionnement
du deuxième organe d'orientation (16 ; 216) dans la cavité du moule le long d'un deuxième
des bords opposés (24, 26).
10. Procédé selon la revendication 8 ou 9, dans lequel ladite étape d'orientation est
en outre définie comme l'orientation de la surface de support de charge moulée (12)
en utilisant un appareil d'orientation capable d'allonger la surface de support de
charge (12), l'appareil d'orientation s'accouplant uniquement avec le premier organe
d'orientation (14 ; 214 ; 314 ; 414 ; 514) et le deuxième organe d'orientation (16
; 216), l'appareil d'orientation déplaçant le premier organe d'orientation (14 ; 214
; 314 ; 414 ; 514) et le deuxième organe d'orientation (16 ; 216) à l'écart l'un de
l'autre de manière à allonger la surface de support de charge (12).
11. Procédé selon l'une quelconque des revendications 8 à 10, comportant en outre l'étape
consistant à monter l'ensemble de support de charge (10 ; 210 ; 310 ; 510 ; 610 ;
710) sur une structure de support, ladite étape de montage comportant la fixation
du premier organe d'orientation (14 ; 214 ; 314 ; 414 ; 514) à la structure de support
et la fixation du deuxième organe d'orientation (16 ; 216) à la structure de support,
le premier organe d'orientation (14 ; 214 ; 314 ; 414 ; 514) et le deuxième organe
d'orientation (16 ; 216) étant montés à l'écart l'un de l'autre à une distance déterminée
pour suspendre la surface de support de charge (12) avec une tension souhaitée.
12. Procédé selon l'une quelconque des revendications 7 à 11, comportant en outre l'étape
consistant à monter l'ensemble de support de charge (10 ; 210 ; 310 ; 510 ; 610 ;
710) sur une structure de support, ladite état de montage comportant la fixation de
l'organe d'orientation (14, 16 ; 214, 216 ; 314 ; 414 ; 514) à la structure de support.
13. Procédé selon l'une quelconque des revendications 7 à 12, comportant en outre les
étapes suivantes : fournir à la surface de support de charge (12) un ensemble de connecteurs
intégrés (250, 252 ; 630, 632 ; 730, 732) pour joindre des ensembles de support de
charge adjacents (10 ; 210 ; 310 ; 510 ; 610 ; 710), l'ensemble de connecteurs intégrés
comportant un premier connecteur (250 ; 630 ; 730) sur un côté de la surface de support
de charge (12) et un deuxième connecteur (252 ; 632 ; 732) sur le côté opposé de la
surface de support de charge (12), le premier connecteur étant configuré pour s'emboîter
avec le deuxième connecteur (252 ; 632 ; 732) ; et
emboîter un premier ensemble de surface de support de charge (10 ; 210 ; 310 ; 510
; 610 ; 710) avec un deuxième ensemble de surface de support de charge (10 ; 210 ;
310 ; 510 ; 610 ; 710) en emboîtant le premier connecteur (250 ; 630 ; 730) du premier
ensemble de surface de support de charge avec le deuxième connecteur (252 ; 632 ;
732) du deuxième ensemble de surface de support de charge.